Solar module mounting system

Abstract

Systems and methods for mounting one or more framed solar modules are disclosed. A solar module mounting system can include a plurality of support members configured to support one or more framed solar modules above a mounting surface, such as the ground or the roof of a building. The support members can include rails formed from a rigid material, such as steel. The solar module mounting system can also include a plurality of attachment mechanisms each configured to secure a portion of a framed solar module to a portion of a respective one of the support members.

What is claimed is: 
     
       1. A system for supporting a framed solar module above a mounting surface, the system comprising:
 a first support member extending along the mounting surface; 
 a second support member coupled with the first support member and extending away from the mounting surface, the first support member and the second support member forming a support structure to support a framed solar module; 
 a first ballast rail extending in a direction parallel to the mounting surface and perpendicular to the first support member, the first ballast rail comprising a first 
 ballast support surface and a first sidewall coupled with the first ballast support surface, the first ballast support surface configured to support a first side of a ballast block; and 
 a second ballast rail opposed to the first ballast rail and extending parallel to the first ballast rail, the second ballast rail comprising a second ballast support surface and a second sidewall coupled with the second ballast support surface, the second ballast support surface configured to support a second side of the ballast block opposite the first side of the ballast block, 
 wherein at least one of the first ballast rail and the second ballast rail includes a security tab at at least one end thereof to prevent the ballast block from sliding off either the first ballast support surface or the second ballast support surface. 
 
     
     
       2. The system of  claim 1 , wherein the first ballast support surface of the first ballast rail is spaced away from the second ballast support surface of the second ballast rail. 
     
     
       3. The system of  claim 1 , further comprising a third ballast rail extending parallel to the first ballast rail, the third ballast rail comprising a third ballast support surface that overlaps at least a portion of the first ballast support surface of the first ballast rail and a third sidewall that overlaps at least a portion of the first sidewall of the first ballast rail. 
     
     
       4. The system of  claim 3 , wherein the first ballast rail comprises a first interlocking feature configured to interlock with a second interlocking feature of the third ballast rail. 
     
     
       5. The system of  claim 3 , further comprising a mechanical fastener that couples the first ballast rail and the third ballast rail with the first support member. 
     
     
       6. The system of  claim 1 , wherein the first ballast rail and the second ballast rail are positioned beneath the framed solar module. 
     
     
       7. The system of  claim 1 , wherein the first ballast rail comprises a security tab configured to prevent the ballast block from sliding off of the first ballast support surface. 
     
     
       8. A ballast rail, comprising:
 a metal sheet formed into a shape having one or more angles to provide:
 a ballast support surface configured to support a side of a ballast block; 
 a sidewall upwardly extending away from the ballast support surface and coupled with the ballast support surface; 
 an interlocking feature that includes at least a portion of one of the sidewall or the ballast support surface and configured to interlock with another interlocking feature of another ballast rail; and 
 wherein at least one end of the ballast support surface includes one or more openings that enable the ballast rail to be aligned with one or more mounting holes of a support member for mounting the ballast rail. 
 
 
     
     
       9. The ballast rail of  claim 8 , wherein the ballast rail is formed from a single metal sheet. 
     
     
       10. The ballast rail of  claim 8 , wherein the metal sheet comprises one of steel or aluminum. 
     
     
       11. The ballast rail of  claim 8 , wherein the shape of each of the ballast support surface, the sidewall and the interlocking feature is selected to reduce stress from bending to prevent permanent deformation of the ballast rail under load. 
     
     
       12. The ballast rail of  claim 8 , wherein the interlocking feature is formed at a juncture of the ballast support surface and the sidewall. 
     
     
       13. The ballast rail of  claim 8 , wherein the interlocking feature is configured to interlock to a second interlocking feature of a second ballast rail to function as one ballast rail with a length longer than a length of one of the ballast rail or the second ballast rail. 
     
     
       14. The ballast rail of  claim 8 , wherein the metal sheet is formed to include a security tab at least at one end of the ballast rail to prevent the ballast block from sliding off the ballast support surface. 
     
     
       15. The ballast rail of  claim 14 , wherein the security tab is bendable at an angle with respect to the sidewall. 
     
     
       16. A system for supporting a ballast using one or more ballast rails, the system comprising:
 a ballast rail comprising:
 a ballast support surface configured to support at least a portion of a ballast block and to be substantially parallel to a mounting surface; 
 a sidewall upwardly extending away from the ballast support surface and coupled with the ballast support surface; and 
 an interlocking feature at a juncture of the sidewall and the ballast support surface forming an angle less than ninety degrees; and 
 
 wherein the ballast rail is configured to be mounted to a support member such that the ballast rail extends in a direction perpendicular to the support member; 
 wherein a shape of the ballast support surface and the sidewall and the angle of the interlocking feature of the ballast rail are configured to withstand a load without permanent deformation of the ballast rail, and 
 wherein the ballast rail further includes a security tab at at least one end of the ballast rail to prevent the ballast block from sliding off the ballast support surface. 
 
     
     
       17. The system of  claim 16 , wherein the shape of the ballast support surface and the sidewall and the angle of the interlocking feature of the ballast rail are formed from a single metal sheet. 
     
     
       18. The system of  claim 16 , wherein at least one end of the ballast support surface includes one or more openings that enable the ballast rail to be aligned with one or more mounting holes of the support member for receiving a mechanical fastener to mount the ballast rail. 
     
     
       19. The system of  claim 17 , wherein a plurality of openings of the ballast rail having the one or more openings are positioned at different positions along a length of the ballast rail such that the ballast rail is able to be repositioned and fastened to the support member at a time of installation based at least on a location of the one or more mounting holes. 
     
     
       20. The system of  claim 16 , wherein the interlocking feature is configured to interlock with another interlocking feature of another ballast rail.